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Abstract:

The present invention concerns a process for manufacturing facing panels
in composite material (1) which can be applied to structural and not
structural walls, to ceilings, to mobile or fixed surfaces, both inner
and external of buildings, enclosures or other structures, mainly, but
not exclusively, in home-building field or be used as separate and
independent walls too. The invention further concerns the panel (1) built
through this process. It allows to make decorative, facing and insulating
panels (1) whose thickness changes according to the kind of material (3),
which basically reproduce any natural materials, such as stone(s) (14),
rock(s), marble, wood and not, for example bricks (15) or other finishes
with random shapes at variable height differences (5) in plane or curved
surfaces, reducing costs and laying time with great flexibility and easy
of use.

Claims:

1-8. (canceled)

9. A process for manufacturing a facing panel in composite material
resembling a visible surface with random shapes at variable height
differences or natural materials such as stone(s), rock(s), marble, wood,
brick(s) or other desired material, said process comprising: a) shaping a
support panel; b) introducing and arranging said support panel; c)
preparing a composition of a mixture; d) uniformly spreading said
mixture(s) on the support panel; e) uniformly spreading a release agent;
f) moulding and shaping said mixture(s); wherein before hardening of
mixture(s), a possible plastic deformation of said support panel can be
provided so that said support panel can assume a desired configuration.

10. The process as claimed in claim 9, wherein the panel comprises a
reticular additional support made by a reinforcing net-like structure.

11. The process as claimed in claim 10, wherein the reinforcing net-like
structure is spread between step b) and step c).

12. The process as claimed in claim 10, wherein the reinforcing net-like
structure is embedded in the mixture(s).

13. The process as claimed in claim 10, wherein the reinforcing net-like
structure is embedded in the mixture(s) after spreading d) of the
mixture(s).

14. The process as claimed in claim 10, wherein the reinforcing net-like
structure is applied between the mixture(s) and the support panel.

15. The process as claimed in claim 9, wherein said support panel is of a
material different with respect to the mixture(s).

16. The process as claimed in claim 9, wherein moulding said mixture(s)
determines a visible surface finish resembling the surface of articles
made of natural materials comprising stone(s), rocks, marble, wood,
metals and not brick(s) or other finishes with random patterns and shapes
at variable height differences in plane or curved surfaces.

17. Facing panel in composite material and resembling the visible surface
with random shapes at variable height differences or natural materials
such as stone(s), rock(s), marble, wood, brick(s) or other desired
material, said panel comprising a support panel on which at least one
layer of mixture(s) is provided.

18. The facing panel as claimed in claim 9, wherein the mixture comprises
mineral granule substances and an artificial material comprising at least
one of cement, plastic substances, or a combination thereof.

22. The facing panel as claimed in claim 17, wherein said panel is
configured to be applied to structures including buildings walls,
frameworks or similar, ceilings, enclosures, prefabricated or mobile
structures or can be configured as a separate and independent wall.

23. The facing panel as claimed in claim 17, wherein said panel is
perimetrally provided with one or more joints with at least one recess or
protrusion configured to fit with an adjacent panel shape.

24. The facing panel as claimed in claim 17, wherein said panel is
provided with one or more lap joints.

Description:

AREA OF APPLICABILITY

[0001] The present invention concerns a process for manufacturing facing
panels in composite material (1) which can be applied to structural and
not structural walls, to ceilings, to mobile or fixed surfaces, both
inner and external of buildings, enclosures or other structures, mainly,
but not exclusively, in home-building field or be used as separate and
independent walls too.

[0002] The invention further concerns the panel (1) built through this
process. It allows to make decorative, facing and insulating panels (1)
whose thickness changes according to the kind of material (3), which
basically reproduce any natural materials, such as stone (14), rock,
stone, marble, wood and not, for example bricks (15) or other finishes
with random shapes at variable height differences (5) in plane or curved
surfaces, reducing costs and laying time with great flexibility and easy
of use.

STATE OF THE ART

[0003] The use of various prefabricated panels reproducing the outer
surface of building structures of stone, rocks, masonry or wood, for
covering bearing structures of buildings such walls, columns, arches,
frameworks or similar both as a protection and a decoration, is well
known.

[0004] Examples of implementation of these panels are shown for example in
patent documents DE2512460 and U.S. Pat. No. 5,735,094.

[0005] In particular it is further known a process for manufacturing
panels by using a mixture of cement and inert materials poured into
suitable moulds shaped according to the article to reproduce.

[0006] When the panel is hardened is extracted from the mould and painted
on the visible side.

[0007] However these panels show some drawbacks, they are very heavy and
it is difficult making them curved or moulded.

[0008] Besides such panels do not offer insulation to the wall to protect.

[0009] Another embodiment is manufacturing panels in fibreglass: they can
be moulded during the production phase at discretion and must necessarily
show a high thickness to have a suitable stiffness and mechanical
resistance. Even in this case the panel is painted on the surface and it
involves color scraping in the long run.

[0010] Besides this kind of panels has not insulating characteristics
either.

[0011] Another embodiment is manufacturing panels made from a mixture of a
resin and granules of mineral substances, poured in fluid form into
suitable moulds shaped according to the article to reproduce.

[0012] When the panel is hardened is extracted from the mould which
determines its shape and sizes but this process shows some limits,
excludes coupling to other materials during the production phase.

[0013] Such panels have a good mechanical stiffness but not insulating
properties. Besides the use of various panels with insulating function
made of several natural and artificial materials such as cork, wood fibre
and other vegetable fibres, polyurethane, polystyrene and other
artificial insulating materials is well known but these ones must be
protected and faced after exposure with traditional materials such as
metals, wood, plasters and others; periodical maintenance and painting
are necessary.

[0014] Traditional technique of such insulating raw or semi-processed
panels application to external or inner of the buildings to isolate
through adhesive on the back and screws which pass through them in their
thickness, provoking thermal transmittance (thermal leak) which transmit
heat, cold and noises is also known.

[0015] Another drawback of such technique is that visible protective
coating facing, generally plaster, creates an overall surface increasing
cracks risk due to building smallest movements or the various materials
expansion due to temperature changes.

[0016] It is an object of the present invention manufacturing modular
protective facing and decorative panels (1), resembling the surface of
articles made of natural materials such as stones (14), rock(s), marble,
wood, metal or artificial materials with random shapes and patterns for
example brick(s) (15) and in the meanwhile insulation compared to
presently known solutions.

[0017] Another object of the invention is manufacturing insulating facing
panels (1) which can be shaped at discretion during the production phase
and without sizes limits, with the possibility to change support material
kind (3) easily, facilitate the laying and create a protective barrier to
atmospheric agents.

[0018] Another object of the invention is such panels mechanical
application with various embodiments, to avoid thermal transmittance
(thermal leak).

[0019] The applicant, to solve known technique drawbacks, to reach
above-mentioned objects and obtain further advantages, has designed and
made the present invention.

INVENTION DESCRIPTION

[0020] The present invention is essentially recited and characterized in
independent claims.

[0021] Other innovative characteristics of the invention are recited in
dependent claims.

[0022] According to the invention the facing panel is made of a mixture(s)
of cement base and mineral granules at least (2).

[0026] In a preferred embodiment the mixture(s) (2) comprises some natural
or artificial fibres.

[0027] In an embodiment of the invention the panel shows a mixture(s)
shallow layer (2) combined to a different material layer (3).

[0028] In a possible manufacturing form the panel shows at least partially
arched, corrugated or differently shaped configuration.

[0029] According to a variation the panel shows perimetrally some joints
with a least a recess or a protrusion (6) to better fit with an adjacent
panel shape (FIG. 6).

[0030] According to a variation the panel (1) shows one or more lap joints
(7) with variable thickness and shapes, to better set an insulating
sealing (with complete thermal break).

[0031] Advantageously such panel (1), besides being applied to structures
such as buildings walls, frameworks or similar, ceilings, enclosures,
prefabricated fixed or mobile structures, can be also used as separate
and independent wall.

[0032] A process for manufacturing a panel (1) according to the invention
comprises the following steps at least:

[0033] a) shaping of the support panel (3);

[0034] b) introduction and arrangement of the support panel (3);

[0035] c) mixture's (2) composition preparation;

[0036] d) uniform spreading of the mixture(s) (2);

[0037] e) uniform spreading of the release agent;

[0038] f) moulding and shaping of the mixture(s) (2).

[0039] In a preferred manufacturing embodiment the panel shows a reticular
additional support made by a reinforcing net (4) embedded in the
mixture(s) (2).

[0040] In another preferred manufacturing embodiment such reticular part
(4) is applied between the mixture(s) (2) and the support panel (3).

[0041] In another preferred manufacturing embodiment the reticular
additional support made by a reinforcing net-like structure (4) can be
embedded in the mixture(s) (2) after its spreading.

[0042] In another preferred manufacturing embodiment of the invention can
be reproduce the surface of articles made of natural materials such as
stones (14), 120 rock(s), marble, wood, metal or artificial materials
with random shapes and patterns at variable height differences (5) for
example brick(s) (15) in plane or curved surfaces, determined by the
molding.

[0043] In another preferred manufacturing embodiment of the invention,
before mixture(s) (2) hardening, forecasting a plastic deformation of
such panel is 125 possible so it can assume a desired configuration, for
example angles, arches, undulations and so on or it can be shaped in any
other desired shape.

DRAWINGS ILLUSTRATION

[0044] These and other characteristics of the present invention will be
disclosed in the following description of a preferred manufacturing form,
supplied as an example, not limiting, with reference to attached drawings
in which:

[0045] The FIGS. 1 and 2 schematically illustrates a front view of a
facing panel according to the invention;

[0046] FIG. 3 schematically illustrates a partially sectioned front view
of a facing panel according to the invention;